U.S. patent number 10,427,505 [Application Number 15/617,641] was granted by the patent office on 2019-10-01 for roof module for a vehicle and method for manufacturing a roof module.
This patent grant is currently assigned to ROOF SYSTEMS GERMANY GMBH. The grantee listed for this patent is Roof Systems Germany GmbH. Invention is credited to Maximilian Kirchner, Matthias Ludwig, Joachim Roder, Markus Waroch.
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United States Patent |
10,427,505 |
Kirchner , et al. |
October 1, 2019 |
Roof module for a vehicle and method for manufacturing a roof
module
Abstract
A roof module for a motor vehicle comprises an RTM frame and a
Class-A covering layer, which at least partially covers the frame
and is made of polyurethane. A method for manufacturing a roof
module comprises the following steps: Initially, a fiber mat is put
into a first mold. Then, a reactive resin system is introduced into
the closed mold and the resin cures, so that a blank is formed. The
blank is put into a second mold, into which subsequently
polyurethane is introduced in the open condition. The polyurethane
expands, wherein it at least partially forms a Class-A surface.
Inventors: |
Kirchner; Maximilian
(Schluechtern, DE), Ludwig; Matthias (Vechelde,
DE), Roder; Joachim (Muehlheim, DE),
Waroch; Markus (Gifhorn, DE) |
Applicant: |
Name |
City |
State |
Country |
Type |
Roof Systems Germany GmbH |
Dietzenbach |
N/A |
DE |
|
|
Assignee: |
ROOF SYSTEMS GERMANY GMBH
(Dietzenbach, DE)
|
Family
ID: |
59522717 |
Appl.
No.: |
15/617,641 |
Filed: |
June 8, 2017 |
Prior Publication Data
|
|
|
|
Document
Identifier |
Publication Date |
|
US 20170355401 A1 |
Dec 14, 2017 |
|
Foreign Application Priority Data
|
|
|
|
|
Jun 8, 2016 [DE] |
|
|
10 2016 110 586 |
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B29C
69/02 (20130101); B60J 7/00 (20130101); B62D
25/06 (20130101); B29C 70/202 (20130101); B29C
70/48 (20130101); B62D 29/043 (20130101); B29C
44/332 (20161101); B29L 2031/3002 (20130101); B29C
59/02 (20130101); B29K 2075/00 (20130101); B29K
2309/08 (20130101); B29K 2105/256 (20130101); B60Y
2410/122 (20130101) |
Current International
Class: |
B60J
7/00 (20060101); B62D 29/04 (20060101); B29C
70/20 (20060101); B29C 70/48 (20060101); B62D
25/06 (20060101); B29C 69/02 (20060101); B29C
44/32 (20060101); B29C 59/02 (20060101) |
Field of
Search: |
;296/210,216.01 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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10229473 |
|
Jun 2003 |
|
DE |
|
102007019738 |
|
Oct 2008 |
|
DE |
|
102008033923 |
|
Jan 2010 |
|
DE |
|
102008035918 |
|
Feb 2010 |
|
DE |
|
102012104542 |
|
Nov 2013 |
|
DE |
|
102012111350 |
|
May 2014 |
|
DE |
|
2521937 |
|
Jul 2015 |
|
GB |
|
Primary Examiner: Pedder; Dennis H
Attorney, Agent or Firm: Dilworth IP, LLC
Claims
What is claimed is:
1. A sun roof module adapted to be placed in a vehicle body
structure of a motor vehicle, the sun roof module including an RTM
frame and a Class-A covering layer, which at least partially covers
the frame and is made of polyurethane, the Class-A covering layer
being fiber-free, wherein the RTM frame includes a fiber mat, and
wherein the fiber mat is free from seams at least in the region of
the Class A covering layer.
2. The roof module of claim 1 wherein the RTM frame is a
polyurethane component.
3. The roof module of claim 1 wherein the fiber mat contains glass
fibers.
4. The roof module of claim 3 wherein the glass fiber content of
the frame lies between 40% and 60%.
5. The roof module of claim 1 wherein the fiber mat is
multi-layered.
6. The roof module of claim 1 wherein between the RTM frame and the
covering layer a film is arranged.
7. The roof module of claim 6 wherein the film is made of
thermoplastic material.
8. A sun roof module adapted to be placed in a vehicle body
structure of a motor vehicle, the sun roof module including an RTM
frame and a Class-A covering layer, which at least partially covers
the frame and is made of polyurethane, the Class-A covering layer
being fiber-free, wherein the RTM frame includes a fiber mat,
wherein the fiber mat contains glass fibers, and wherein the glass
fiber content of the frame lies between 40% and 60%.
9. The roof module of claim 8 wherein the fiber mat is
multi-layered.
10. The roof module of claim 8 wherein between the RTM frame and
the covering layer a film is arranged.
11. The roof module of claim 10 wherein the film is made of
thermoplastic material.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
This application claims priority under 35 U.S.C. 119 to the
following German Patent Application No. DE 10 2016 110 586.4 filed
on Jun. 8, 2016, the entire contents of which are incorporated
herein by reference thereto.
TECHNICAL FIELD
The invention relates to a roof module for a motor vehicle and a
method for manufacturing a roof module for a motor vehicle.
BACKGROUND OF THE INVENTION
From the prior art numerous roof modules are known already, which
are designed as composite plastic components. Due to their low
weight, the simple shape and the better adjustability of the
material properties, these composite components frequently replace
conventional vehicle roof modules or exterior claddings of vehicle
bodies, which are made of glass or sheet metal.
Such roof modules are particularly advantageous when they are
supplied as pre-mounted assembly which then is connected with the
rest of the bodyshell (i.e. in particular the longitudinal and
transverse struts which usually extend between the two A-pillars,
the two B-pillars and the two C-pillars).
It is the object of the invention to create a roof module which is
characterized by improved properties, i.e. in particular higher
strength, lower weight and/or higher-quality surface.
BRIEF DESCRIPTION OF THE INVENTION
This object is achieved with a roof module for a motor vehicle is
provided in accordance with the invention, comprising an RTM frame
and a Class-A covering layer which at least partially covers the
frame and is made of polyurethane. For the solution of this object
there is furthermore provided a method for manufacturing a roof
module by means of the following steps: Initially, a fiber mat is
put into a first mold. Then, a reactive resin system is introduced
into the closed mold and the resin cures, so that a blank is
formed. The blank is put into a second mold, into which
subsequently polyurethane is introduced in the open condition. The
polyurethane expands, wherein it at least partially forms a Class-A
surface.
The invention is based on the finding that excellent properties can
be achieved by the combination of an RTM frame with a foam cladding
of polyurethane. On the one hand, the frame is characterized by a
high rigidity. On the other hand, in regions which in the mounted
roof module are visible from outside a Class-A surface can be
obtained with comparatively little effort, without separate
attachment parts having to be mounted on the frame for this
purpose, as it often is the case in the prior art. This leads to
weight advantages. Furthermore, the Class-A surface of polyurethane
is of very high quality, as it can be realized with a self-healing
surface. If desired, the Class-A surface also can be polished.
The term RTM frame here designates a frame which is manufactured by
the so-called RTM method. RTM stands for "Resin Transfer Molding"
and also is known by the term "resin injection method". In this
method an unimpregnated fiber mat is put into a mold, and after
closing of the mold a reactive resin system is introduced into the
mold cavity of the mold. The resin system fully soaks the fiber mat
and cures. Subsequently, a blank can be removed from the mold.
For the RTM method various reactive resin systems are conceivable.
Polyurethane, however, is particularly preferred, as it leads to
very good results as regards its properties.
The RTM frame preferably includes a fiber mat which in particular
can contain glass fibers. This provides a very high component
strength.
The fiber content of the frame lies between 40% and 60%. What is
particularly preferred is a glass fiber content of 45%.
The fiber mat preferably is multi-layered. This provides for
aligning the fibers in the individual layers corresponding to the
component load, whereby the stiffness of the frame is
optimized.
According to a preferred embodiment of the invention the fiber mat
is free from seams at least in the region of the Class-A covering
layer. In principle such seams are advantageous, in order to
suitably drape the different layers of the fiber mat. It was found
out, however, that the surface quality of the Class-A covering
layer is better when the fiber mat is completely free there from
seams.
According to one aspect of the invention it is provided that
between the RTM frame and the covering layer a film is arranged.
The film, which in particular is made of thermoplastic material,
acts as thermal insulation and adhesion promoter between the RTM
frame and the covering layer, whereby on the one hand the surface
qualities of the Class-A covering layer are increased and on the
other hand a better connection between the covering layer and the
frame is obtained.
To adapt the covering layer to the respective wishes of the
customer, it is possible to color the polyurethane introduced into
the second mold. Then, it no longer is necessary to paint the
finished roof module.
According to one aspect of the invention it is provided that the
fiber mat is pre-embossed before it is put into the first mold. It
thereby is possible to also realize more complex geometries of the
frame, without any problems arising when carrying out the RTM
method.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described below with reference to various
embodiments which are illustrated in the attached drawings, in
which:
FIG. 1 shows a perspective view of a roof module according to the
invention;
FIGS. 2a to 2c show various method steps in the manufacture of a
blank;
FIG. 3 schematically shows a section through a fiber mat which can
be used in the manufacture of the blank;
FIGS. 4a to 4c show various steps in the manufacture of the Class-A
covering layer; and
FIGS. 5a to 5c show a roof module according to a second embodiment
of the invention in various views.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 schematically shows a roof module 10 according to a first
embodiment. It here consists of an RTM frame 12 which in certain
parts or portions is provided with a Class-A covering layer 14.
The roof module 10 is provided to be mounted on a motor vehicle. In
particular, it is connected with the bodyshell. Depending on the
design of the roof module it can form part of the roof surface of
the body or the entire roof surface. The roof module for example
can be arranged in the region between the two A-pillars or the two
B-pillars.
The frame 12 includes a front transverse strut 16 and a rear
transverse strut 18. The same are connected with each other by two
side struts 20. All struts are formed integrally with each
other.
The struts 16, 18, 20 are suitably profiled, so that a lid (not
shown here) can be mounted on the same. The lid in particular can
be transparent.
Depending on the embodiment the lid can be firmly connected with
the frame 12, in particular be glued to the same. In this case, the
struts of the frame 12 are profiled such that the desired
connecting surfaces for the lid are produced.
A transparent lid also can be an adjustable lid of a sliding roof
system. In this case, the struts 16, 18, 20 are profiled such that
the desired fastening points for the mechanism of the sliding roof,
the shading device, holders for cable ducts, water channels and/or
other assembly configurations are obtained.
In the embodiment shown in FIG. 1, the Class-A covering layer 14 is
designed in the manner of a trim which here extends across the
entire width of the front strut 16. In the mounted condition of the
roof module 10 the Class-A covering layer 14 hence adjoins the
upper edge of the windshield of the vehicle.
The Class-A covering layer 14 is no separate component, but
directly foamed onto the frame 12. Its surface has a structure
which resembles that of a painted sheet-metal surface, so that in
principle it can be part of the outer surface of a vehicle body
without any further aftertreatment.
With reference to FIGS. 2a to 2c the manufacture of the frame 12
will be explained below.
For manufacturing the frame 12 a mold 30 is used, which includes
two mold parts 32, 34. Between the two mold parts 32, 34 a fiber
mat 36 is placed. It is designed multi-layered (see FIG. 3),
wherein the fiber direction of the individual layers is adjusted to
the future component load. This in particular is a multilayer glass
fiber mat.
The fiber mat (also known as "preform") already has the basic
geometry of the frame 12. In the exemplary embodiment shown in FIG.
1 the fiber mat 36 hence has a frame-like, rectangular shape with a
large central cutout.
When it is put into the first mold 30, the fiber mat 36 usually is
pre-embossed, so that its profiling already resembles the profiling
of the finished frame 12. In addition, the fiber mat can be
provided with a plurality of seams 38 indicated in FIG. 3, which
supports draping of the individual fiber layers.
The pre-embossed fiber mat 36, without being impregnated with
resin, is placed between the two parts 32, 34 of the mold, and the
mold is closed (see FIG. 2a).
Subsequently, a reactive resin system is introduced into the first
mold 30 (see FIG. 2b). The reactive resin system preferably is
polyisocyanate.
In the mold 30, the resin system impregnates the fiber mat
(symbolized in FIG. 2b by a central sprue, from which the resin
system spreads in the mold cavity of the mold and thereby
impregnates the fiber mat) and cures.
Subsequently, the mold 30 can be opened (see FIG. 2c) and a blank
of the frame can be removed.
In a second mold 40 the Class-A covering layer 14 is applied onto
the blank (see FIGS. 4a to 4c).
The second mold 40 also consists of two parts 42, 44. In contrast
to the first mold 30, the second mold 40 has no sprue region.
In a first step the blank 12' is put into the open second mold 40.
Subsequently, a reactive resin system is applied onto the region of
the blank 12' which is to be provided with the covering layer 14.
This is symbolized by a schematically indicated spray head 46.
Subsequently, the second mold is closed (see FIG. 4b) and the
reactive resin system cures. This is a foaming process which
ensures that a smooth mold surface of the second mold present in
the region of the covering layer 14 to be produced is impressed as
Class-A surface.
According to a design variant illustrated in FIGS. 4a to 4c it can
be provided that a film 48 is put into the second mold, which
serves as thermal insulation and as adhesion promoter between the
blank 12' and the covering layer 14 foamed to the same. The film 48
in particular can be made of thermoplastic material.
In FIGS. 5a to 5c a second embodiment 10 is shown. It can be seen
that the frame 12 is designed very much longer than in the first
embodiment. It here extends along longitudinal beams 50 of the
bodyshell proceeding from the A-pillar 52, i.e. adjoining the
windshield, over the B-pillars 54 into the region between the
C-pillars 56. In addition to the front strut 16 and to the rear
strut 18 the frame 12 also is provided with a middle strut 19.
On the frame 12 a front lid 21 and a rear lid 22 are mounted. In
the illustrated exemplary embodiment the front lid 21 is shiftable
in longitudinal direction of the vehicle, while the rear lid 22 is
firmly mounted on the frame 12 and hence on the roof module 10.
In principle, the rear lid also can be shiftably mounted.
Before the front lid 21 the frame 12 is provided with a Class-A
covering layer 14. Behind the rear transverse strut 18 of the frame
a roof surface 58 of the vehicle body is located.
Although in the second embodiment the covering layer 14 only is
shown at the front edge, a further covering layer can of course
also be present between the rear lid and the roof surface of the
vehicle body. It likewise is possible to use a covering layer only
at the rear edge of the roof module.
* * * * *